Content
02 Indorama Pavilion
04
manufacture technique
material
upcycling process
Material Workflow of Project
CONSUMER WASTE INDUSTRIAL WASTE TWISTING
WARPING
SIZING
DRAWING-IN
WEAVING ULTRASONIC WELDING
SORTING COLLECTING WINDING ULTRASONIC WELDING
WOVEN/ KNITTING
rPET GRINDING
MELTING
WINDING
BALING
OPENING NON-WOVEN
CARDING
CROSSLAPPING
NEEDLE PUNCHING
HEAT PRESS
WASHING
Non-woven Panel
rPP PELLETIZING
05
WINDING
MELTING
EXTRUDING
COOLING
PULLING
CUTTING EXTRUSION
rPETG MELTING
EXTRUDING ROBOTIC PRINTING
03
General Circular Economy Diagram recycling specifications 0-25%
shredding/washing/separating 34-60%
sorting collector 2-5%
compounding and yarning specs
0-5% heat reclycling 5-100%
extrusion non woven blow molding
0-2%
0%
land fill 30-60-100%
woven/kinitting thermal forming injection forming rotational molding
new materials made from trash 100% re-recyclable appilcation
MAC Ward
01 Concrete Fromwork
Content ｜ 01
SPINNING
Fitness Pavilion
01 PETG Concrete formawork Professional Group Project Nov.2021 – Jan.2022 Practical Design Project
Introduction As a collaboration with ROSO COOP, the project focused on using PETG, a plastic material, to form a concrete formwork instead of traditional uses of wood and aluminum. Made by a robotic arm, not only does the formwork enable a high degree of customisation, it is also more cost efficient, sustainable and recyclable. This research could be modified to be a modular sysyem. To ensure maximum level of safety of the formwork, my role included running a precise analysis of the lateral pressure support required and performing manipulations through further adjustments in the structural design.
Exploded View
Workflow PETG female mold
ROBOTIC PRINTING
CASTING
Fixture
Overhangs
PETG male mold
Robot Workspace Printing Position
#3 rebar Formwork for forklift
DESIGN TOOL
#3 rebar Formwork for foundation Geometry Design
Opening
Printing Path
Drop 1
Supports
Formwork Static Test The lateral pressure of concrete materials is affected by temperature and the velocity of impact. To test the maximum stress that can be borne by the formwork, the temperature was set at 20 degrees and velocity at 2.2/hr, 1.1m/hr and 0.55m/hr.
Demountable
Formworks
Analysis
Drop 2 The Drop System
male mold
1hr max stress
2hr max stress
4hr max stress
1hr max stress
2hr max stress
4hr max stress
1hr max stress fail
2hr max stress fail
4hr max stress fail
1hr max stress fail
2hr max stress fail
4hr max stress safe
female mold
without supporting
without supporting adding supporting
with supporting
finishing
Concrete Formwork ｜ 02
Type Robotic Fabrication Site Taichung, Taiwan Supervisor Shih-Yuan Wang yuan@arch.nctu.edu.tw Role Structural Analysis Detail Design & Optimization
02 HHBL Indorama Pavilion Professional Group Project Mar.2018 – July.2018 Practical Design Project
Introduction Located near Suvarnabhumi Airpot, spanning across 350 sq.m., the Indorama Pavilion was the first tension pavilion built by HHBL. The structure system of the pavilion was to be erected before the shape of the canopy was formed. Cables were inserted through the canopy, not only controlling the shape and aesthetic of the pavillion, but also avoiding water captured in-between the fabric. The design of the cables required a precise balance between aesthetics and tension required to hold the structure against weight, force and environmental elements such as wind and rain.
Form Finding
Exploded View Indorama Pavilion ｜ 03
Type Fabric Tensile Structure of Pavilion Site Bangkok, Thailand Supervisor Jarvis Liu - jarvis.liu@miniwiz.com Role Design Assistent Structural Analysis Detail Design & Optimization
With the provided shape and size of the canopy, the structure must be optimised and the pavilion must enable maximum area of public space.
T Y P E 1
T Y P E 2
T Y P E 3
Using four supporting columns, a basic canopy shape was formed and the shaded, usable area was studied.
Two supporting columns were connected into a cross structure as an attempt to increase shaded, usable area.
The canopy was doubled, supported by cantilever beams to reduce the number of columns and increase the shaded, usable area.
cable
rPET fabric
membrane plate 1 supporting pipe main column cantilever beam anchor
membrane plate 2 membrane plate 3
Cable Tension Test The tension of the cable must be precisely calculated to avoid water being captured between the fabric. direction of cable tension
cable tension force :15300N
cable tension force :20850N
cable tension force : 23730N
Wind Simulation The simulation included analysis of wind speed and direction, using Solidworks to simulate pressure and velocity of impact, the degree of force and moment was derived.
S T E P 1
Construction Sequence
Maximum wind speed from the East : 30 km/hr
The construction was more than a simple plan of sequence. Throughout the works, regular tightening of the cable tension was required to ensure rain water would not be captured.
wind rose
pressure distribution
velocity distribution(plan)
velocity distribution(right)
Maximum wind speed from the South : 90km/hr
wind rose
pressure distribution
velocity distribution(plan)
velocity distribution(right)
Static Simulation
S T E P 2
canopy deformation
canopy deformation
whole structure stress
whole structure stress
main columns stress
cantilever beams stress
supporting pipes stress
cables stress
membrane 2 stress
membrane 3 stress
S T E P 3
Assemble cantilever beams on the columns and cross the canopy
S T E P 4
Assemble supporting pipe between cantilever beams and columns
S T E P 5
Set up membrane plates on the canopy and assemble on beams
S T E P 6
Set up membrane plates on the canopy and assemble on anchors
3
4
connection stress
As a result of the structural simulation, we were able to derive the force of each cable followed by designing the membrane plates and each connection detail using such data.
membrane 1 stress
2 Assemble canopy on the top of columns
connection stress
Membrane Plate
S T E P 3
S T E P 2
1 Set up cables on the canopy
membrane 4 stress
S T E P 7
5
6
7 well done
Indorama Pavilion ｜ 04
With the understanding of wind force, each reaction force of the canopy was recorded. Utilising RFEM, the structure elements and characteristics were calculated.
S T E P 1
03 MAC Ward Professional Group Project May.2020 – Mar.2021 Practical Design Project
Introduction As a response to the Covid-19 outbreak, the Fu-Jen Hospital looked to create a modular ward that is flexible and convertible according to varying needs while being able to assemble at a timely and effortless manner.We participated in the design using recycled aluminum (rAluminum) as the structure, including beams, columns, walls and floors. The design incorporated PP extrusion recycled from masks to create a negative pressure ward that also holds all the equipments within the space. Each component was carefully designed and reviewed through static and dynamic analysis. The design presented astonishing results with the ward assembly taking less than 10 hours to be completed.
Exploded View
Whole System Static Test rAluminum main beam
rAluminum sub-beam
I were able to perform static test on the entire system at 1.8 tons (the required impact tolerance level of medical equipment ).
rAluminum ceiling panel
Structure System Connection Static Test The connections were made by steel, joint with each aluminum extrusion. The yield strength of steel is stronger than aluminum at 250MPA.
rAluminum wall panel
connection 1 stress 51.5>250MPA (safe)
ton
1.8
rAluminum sub-column rAluminum main column Electrical channel
connection 2 stress 51.5>250MPA (safe)
Beam and Column System Static Test Several structures and sections were built to study the feasibility of recycled aluminum as a main material. As welding could not be performed on aluminum, all connections were joint using steel plates. The stress test was performed by separating the structure into four columns supporting beams. 300kg of force was placed in the middle of each beam to identify the appropriate system.
section 1 stress: 148>145 (fail)
section 3 stress: 105>145 (pass)
section 2 stress: 112>145 (pass)
type 1 structure deformation Type 1
type 3 structure stress
type 2 structure stress
type 1 structure stress
type 2 structure deformation Type 2
type 4 structure stress section 4 stress: 98.7>145 (safe)
type 3 structure deformation Type 3
type 4 structure deformation Type 4
MAC Ward ｜ 05
Type Modular ward system Site Taipei, Taiwan Supervisor Jose Lopez - jose.lopez@miniwiz.com Role Design Structural Analysis Detail Design & Optimization
Modular System Wind Force Analysis
Exploded View
The modular system consists of several elements including rAluminum wall panels, rAluminum extrusion, PP extrusion and TPV extrusion. Using different levels of wind speed (between lv6-17), each element of the system was tested and data was derived as shown below.
Main rAluminum column rAluminum extrusion T-type nut
Aluminum Wall Panel Static Test
TPV extrusion
Wind level 6
rAluminum wall panel is recycled by aluminum formwork.
Wind level 11
Wind level 15
wind speed: 13.8m/s
wind speed: 32.6m/s
wind speed: 50.9m/s
wind speed: 62m/s
wind force: 23kg/m2
wind force: 128kg/m2
wind force: 312kg/m2
wind force: 500kg/m2
stress : 1.99<145 (safe)
stress : 11.1<145 (safe)
stress : 26.9<145 (safe)
stress : 43.2<145 (safe)
wall panel stress
wall panel stress
wall panel stress
rAluminum wall panel
wall panel stress
PP Extrusion Impact Test
Wind level 6
Wind level 11
Wind level 15
Wind level 17
wind speed: 32.6m/s
wind speed: 50.9m/s
wind speed: 62m/s
wind force: 23kg/m2
wind force: 128kg/m2
wind force: 312kg/m2
wind force: 500kg/m2
stress : 4.6<145 (safe)
stress : 25.2<145 (safe)
stress : 59<145 (safe)
stress : 98.6<145 (safe)
extrusion stress
extrusion stress
extrusion stress
PP Extrusion Static Test
start point 0.85<27.6 (safe)
point 2 21.4<27.6 (safe)
point 3 23.9<27.6 (safe)
end point 9.38<27.6 (safe)
Screw on PP Extrusion Static Test Wind level 6
rPP extrusion is recycled by mask.
Testing buckling when PP extrusion puts into aluminum extrusion.
MAC Ward ｜ 06
wind speed: 13.8m/s
extrusion stress
PP extrusion TPV extrusion
Aluminum Extrusion Static Test
rAluminum extrusion is recycled by aluminum formwork.
M5 screw
Wind level 17
Wind level 11
Wind level 15
Wind level 17
wind speed: 13.8m/s
wind speed: 32.6m/s
wind speed: 50.9m/s
wind speed: 62m/s
wind force: 23kg/m2
wind force: 128kg/m2
wind force: 312kg/m2
wind force: 500kg/m2
stress : 1.68<27.6 (safe) PP extrusion stress
stress : 9.2<27.6 (safe)
stress : 21.5<27.6 (pass)
stress : 36<27.6 (fail)
PP extrusion stress
PP extrusion stress
PP extrusion stress
Testing how much weight that each screw can hold. Maximun weight is 15kg per screw.
5kg 109<250(safe)
10kg 148<250 (safe)
15kg 220<250 (safe)
20kg 291>250 (fail)
04 HHBL Fitness Pavilion Professional Group Project Mar.2019 – Sep.2019 Practical Design Project Form Finding Due to the form of structure is symmetry, I create several types to check which one is most stable to hold the canopy. Trying to find the efficient canopy to avoid puddle and collect rainwater to the center of pavilion.
Fitness Pavilion ｜ 07
Type Fabric Tensile Structure of Pavilion Site Bangkok, Thailand Supervisor Jarvis Liu - jarvis.liu@miniwiz.com Role Leading Design Structural Analysis Detail Design & Optimization Introduction Located near Suvarnabhumi Airport, Bangkok, The Fitness Pavilion was the second tension Pavilion built by HHBL, spanning across 400 sq.m.. The project requested a light weight structure that provides maximum public space for fitness activities. Our design proposed a centralised structural support, minimising the space occupied by beams. The geometric canopy design provides a lighter structure and eliminates water accumulation. A 36 sq.m. planter area was placed in the middle of the pavilion for aesthetics, achieving a 364 sq.m. space for the public to use.
1 2 3 4 5 6 7 8 9 10 11 12 1 type 1 model 2 type 2 model 3 type 3 model 4 type 4 model 5 type 1 canopy deformation 6 type 2 canopy deformation 7 type 3 canopy deformation 8 type 4 canopy deformation 9 type 1 structure stress 10 type 2 structure stress 11 type 3 structure stress 12 type 4 structure stress
Tree-like main column structure was used to achieve a lightweight design.
The canopy was separated into two layers and foundations were centralised to provide more space for public use. Type 1
Type 2
The top structure and the canopy were revised to achieve mechanical equilibrium. Type 3
The whole structure was simplified and the canopies were revised as one layer, avoiding water being captured on the fabric. Type 4
Wind Simulation
Member Simulation
Researching the data of wind speed and direction in Bangkok, and using Solidworks to simulate the value of pressure and velocity. With the calculation of wind pressure, the value of force and moment on canopy come out.
When getting the result of wind force, we can know each reaction force of the canopy. After that, utilising RFEM to calculate the structure members, including columns, beams and cables and optimize the detail of each connection.
pressure distribution
cantilever beam
membrane 1
main columns
membrane 2
lower ring
upper ring
supporting pipe stress
cantilever beam stress
membrane 1 stress
main columns stress
membrane 2 stress
lower ring stress
upper ring stress
supporting pipe deformation
cantilever beam deformation
membrane 1 deformation
main columns deformation
membrane 2 deformation
lower ring deformation
upper ring deformation
velocity distribution(right)
canopy deformation
Construction Sequence Making the structure system first, and then assemble canopy with proper tension.
whole structure stress
Fitness Pavilion ｜ 08
supporting pipe velocity distribution(plan)
05 Ceiling/Wall System Non-woven Panel Professional Group Project Jan.2019 – May.2019 Practical Design Project
Introduction As a R&D project by Miniwiz, the non-woven cross panel is a building material of ceilings and walls. The material is made of felt, which is soft by nature, but becomes hard when it experience heat pressing. With the heat press process, we were able to change the form of felt, leading the team to design molds of panels that can shape the material flexibly. The material assembly was a challenge to overcome, as well as its characteristics. Several revisions were made based on the physical property, fabrication and the assembly of the material. Today, this panel is produced in many interior projects of Miniwiz's.
Manufacture Process
The nature of non-woven felt enables the hard panels to form a structure that supports itself, reducing material wastes and simplifying assembly.
Yarn goes warp way and weft way on the loom, made by interlacing threads at right angles to one another. Yarn goes warp way and weft way on the loom, made by interlacing threads at right angles to one another.
A rectangular panel could not support its weight in a ceiling system. Step 1
A stepped structure design enabled more strength and further shape adjustments made the panels connectible. Step 2
Spray a silver ion coating as the finishing to give the performance of anti-microbial and viral resistance.
Collected bottles will be cut into small pieces, wash and filter several times, then become the rPET flakes. SHREDDER Turn the rPET flakes into liquid and extrude to form filaments yarn then cut into staple fiber. SPINNING Size reduced tufts are split into fibers then unravelled, aerated & paralellized by rollers.
SPRAY COATING
WEB CONSOLIDATION Make a cutting mold to split felt outline into a product. DIE CUTTING One side of the boarder was stretched to connect with another panel, forming the joint area. Step 3
Mold Production
The panels were assembled repeating step 3, forming the entire ceiling system. Step 4
NEEDLE PUNCHING
Static Simulation Weight tests were performed to incorporate light bulbs on the panel.
A flat aluminum panel mold was created to heat press the non-woven felt.
A wooden, curved mold was made to heat press the non-woven felt.
Needles are launched across the batt to create a 3D felt web which fibers entangled vertically
Several felt layers are heat pressed together with a 3D shape mold to form a sheet of panel. HEAT PRESS
1 2 3 4 1 single panel stress 2 single panel deformation 3 ceiling system stress 4 ceiling system deformation
A system made of 6 panels were hung onto the ceiling while each connection point was weight tested and analysed.
Non-woven Panel ｜ 09
Type Interior material R&D Site Taipei, Taiwan Supervisor Jose Lopez - jose.lopez@miniwiz.com Role Design Structural Analysis Detail Design & Optimization
Form Finding